Method of making hollow fiber membrane modules with a curable composition and modules made therefrom

Abstract

A method of making hollow fiber filtration modules including potting an end portion of a plurality of hollow fiber membranes with a multi-pack, solvent-free curable composition. The curable composition includes a Michael donor, a Michael acceptor, and a Michael reaction catalyst.

We claim: 
     
         1 . A method of making a hollow fiber membrane module, comprising:
 preparing a mixture of a multi-pack, solvent-free curable composition by combining a multi-functional Michael donor, a multi-functional Michael acceptor, and a Michael reaction catalyst,   introducing the mixture of the curable composition into at least one end portion of a plurality of hollow fiber membranes, and   allowing the curable composition to solidify and cure, thereby potting the end portion of the plurality of hollow fiber membranes.   
     
     
         2 . The method of  claim 1 , wherein the curable composition further comprises from 0 to less than 10% by weight filler, based on the weight of the curable composition. 
     
     
         3 . The method of  claim 1 , wherein the curable composition exhibits an initial viscosity of from 200 centipoise (cP) to 10,000 cP at 25° C. 
     
     
         4 . The method of  claim 1 , wherein the multi-functional Michael donor comprises an acetoacetylated polyol that has at least one acetoacetoxy functional group, and a skeleton selected from the group consisting of a polyether polyol, a polyester polyol, a polycarbonate polyol, polyurethane polyol, urethane polyol, a polybutadiene polyol, a glycol, a mono-hydric alcohol, a polyhydric alcohol, a natural oil polyol, and modifications thereof, and combinations thereof. 
     
     
         5 . The method of  claim 1 , wherein the multi-functional Michael acceptor is selected from the group consisting of monomers, oligomers, and polymers of multi-functional (meth)acrylate, and combinations thereof. 
     
     
         6 . The method of  claim 5 , wherein the multi-functional Michael acceptor comprises multi-functional polyester acrylates, ethoxylated bisphenol A diacrylates, urethane acrylate oligomers, polyethylene glycol diacrylates, tricyclodecane dimethanol diacrylates, and combinations thereof. 
     
     
         7 . The method of  claim 6 , wherein the curable composition exhibits, upon cure, non-foaming behavior in the presence of moisture. 
     
     
         8 . The method of  claim 6 , wherein urethane acrylate oligomers comprises hexafunctional aromatic urethane acrylate oligomers, aliphatic polyester based urethane hexa-acrylate oligomers, and combinations thereof. 
     
     
         9 . The method of  claim 1 , wherein the catalyst is a strong base catalyst having a conjugate acid that has a pKa of greater than 11. 
     
     
         10 . The method of  claim 1 , wherein the catalyst comprises amindines and guanidines. 
     
     
         11 . The method of  claim 9 , wherein the catalyst comprises 1,1,3,3-tetramethylguanidine (TMG), 1,8-diazabicyclo-[5.4.0]undes-7-ene (DBU), and 1,5-diazabicyclo[4,3,0]non-5-ene (DBN). 
     
     
         12 . The method of  claim 1 , wherein the curable composition exhibits a maximum exotherm temperature of no greater than 120° C. 
     
     
         13 . The method of  claim 1 , wherein the equivalent ratio of Michael acceptor functional group acrylates to Michael donor active hydrogens is from 0.3:1 to 1.5:1. 
     
     
         14 . The method of  claim 1 , wherein the catalyst is in an amount of from 0.1% to 10% based on the mole of Michael active hydrogen atoms. 
     
     
         15 . The method of  claim 1 , wherein the curable composition exhibits a gel time of from 3 minutes to 120 minutes. 
     
     
         16 . The method of  claim 1 , wherein the curable composition exhibits a Shore A hardness of no less than 50 after cured for 7 days at 25° C. and 50% relative humidity. 
     
     
         17 . The method of  claim 1 , wherein the curable composition exhibits a Shore D hardness of no less than 40 after cured for 7 days at 25° C. and 50% relative humidity. 
     
     
         18 . A hollow fiber membrane module, comprising
 a plurality of hollow fiber membranes having at least one end portion potted with a potting composition,   
       wherein the potting composition comprises a reaction product of
 a multi-functional Michael donor, 
 a multi-functional Michael acceptor, and 
 a Michael reaction catalyst. 
 
     
     
         19 . The hollow fiber membrane module of  claim 18 , wherein the potting composition exhibits a Shore A hardness of no less than 50 after cured for 7 days at 25° C. and 50% relative humidity. 
     
     
         20 . The hollow fiber membrane module of  claim 18 , wherein the potting composition exhibits non-foaming behavior in the presence of moisture.